Here’s a table extension I put together last night for the Freud Avanti Plunge Router that’s gotten a lot of press over the past few days. It’s made with some MDF, some scrap 1/2″ maple, 3/4″ oak, and 1/2″ plywood.
From the top, you can access the clamp, height adjustment, and spindle lock. The sides of the table were made from a 1/2″ piece of scrap maple wainscoting, cut in half (one half for each side). The hole on the far left was already there in the scrap piece, so it’s not used here. There are a couple of scrap pieces of oak to support the 3/4″ MDF top. Until I get the right length bolts, I just used a nut to tighten them down. I have a magnetic tray here that holds the adjustment know and wrench — it collects a lot of sawdust from the router, but it’s the only place it really fits.
I never even untied the router cord — tt hangs nicely on the hook I use for the saw fence. When I want to plug it in, I use the table saw outlet and the table saw switch. Remember to turn the router back off if you do this!!!
The insert is 1/2″ plywood. In one of the pictures, you’ll notice that I had to carve a little notch in one of the supports so the locking lever would swing freely. Oops! The extension is mounted with T-nuts and slides out, and drops down for storage. (I guess that what this is useful for, but I pretty much have it up all the time.) The screws that join it all together are countersunk and basically just fasten the sides to the table and the oak supports.
Click for larger views.